Footwear system and method having footwear upper linings for cushioning and shock absorption

ABSTRACT

A footwear systems utilizing silica derived gel sheets used as a footwear component in upper linings of the footwear. The upper linings provide a cushioning and shock absorption system, particularly in inclined high-heel shoes where the toes and MTP (metatarsophalangeal) joints typically bear most of the weight in such shoes and come in contact with the footwear linings. The material advantageously not only provides padding, but also absorbs shock to further reduce force placed on the foot by dissipating energy of each footstep. In addition like material may be disposed in the sole of the shoe under the ball of the foot to provide shock absorption and cushioning below as well.

TECHNICAL FIELD

The invention relates generally to the field of shoe construction. Moreparticularly, the invention relates providing a shoe with resilientstructures to enhance comfort and mitigate fatigue in the foot of auser.

BACKGROUND

Feet are, without doubt, the unsung heroes of human anatomy. Theyliterally carry us on their backs, through thick and thin, and as aresult, feet suffer untold abuse during the course of human activities.Indeed, shoes were likely invented by primitive man to protect theirfeet from crippling injuries, and thereby to increase the durationand/or the vigor of their daily adventures. Such protection couldliterally mean the difference between life and death. As humanexperience progressed, and activities varied, so has our skill,innovation, and objectives with regard to shoe design and construction.

At some point in human history, shoes assumed alternative and/or dualroles as both functional items and objects of aesthetic expression. Sothoroughly has this latter interest developed, that some modern shoeshave completed a historical circuit. They are highly prized and soughtout for their aesthetic qualities, in spite of their tendency to inflictpain and injury upon the user's feet.

For some activities, for example for industrial work and/or athletics,shoes mainly retain functional and injury-prevention purposes, and theirconstruction, including design and materials, are suited primarily forthose purposes. Advancements in knowledge and technology (e.g., materialscience, human anatomy and kinesiology, etc.) have led to thedevelopment of innovative shoe designs, construction, and materials, aswell as staggering levels of use-based specialization in the same. Somuch so, that a shoe designed for a particular purpose (e.g.,sprinting), can include numerous design, material, and constructionvariations depending upon such factors as the type of intended runningsurface, the morphological and kinesthetic characteristics and runningstyle of the individual user, and even the expected weather conditions.

However, the evolution of the design and construction of shoes intendedfor primarily aesthetic (e.g., fashionable) purposes has followed adivergent and rather stunted path. Once established, aesthetics remainsa primary selection criterion by a large segment of consumers, andtherefore also the primary design consideration. This is true despiteresearch showing that wearing shoes that dramatically affect posture,foot angle, balance, and other kinesthetic factors, can and does lead toimproper anatomical alignment and physiological damage taking a host offorms.

Many (primarily women's) fashion shoes feature an elevated heel portion(e.g., high-heels, pumps, platforms, wedges, etc.), which produces ashoe that can be marginally, substantially, or even extremely inclinedalong its anterior-posterior axis. Further, many such shoes includerelatively insubstantial uppers, designed for appearance and to merelyhold their rather rigid sole to the user's foot, rather than to providelateral stability and/or support to the foot during use. As aconsequence of these features, the natural mechanics of the foot areconstrained and compromised, and stresses during use are concentratedinto relatively few, small portions of a user's foot. Namely, the “ball”of the user's foot, and to a somewhat lesser extent, the user's heel, isprimarily affected, as the user's foot is forced into a plantar flexedcondition. As a result of such foot position the force of each footstepis typically concentrated on the toes rather than being distributedalong the whole foot increasing the force felt on the toes, and the ballof the foot,

A secondary market has developed for generically-designed products, eachof which are insertable into a wide variety of functional shoes (e.g.,replaceable, cushioned, full-foot shoe insoles, molded rigid orthotics,heel pads, etc.), to enhance comfort and/or provide, for example,orthopedic benefits. However, products suitable for use in women'sfashion shoes, such as those having an elevated heel and/or relativelyopen or otherwise minimally-enclosing upper portions are sorely lacking.Accordingly, it would be desirable to provide a stylish shoe that iscomfortable to the wearer pads the foot against abrasion and tends toreduce the force felt per unit area by the wearer.

SUMMARY

The following presents a simplified summary of the disclosure in orderto provide a basic understanding to the reader. This summary is not anextensive overview of the disclosure and it does not identifykey/critical elements of the invention or delineate the scope of theinvention. Its sole purpose is to present some concepts disclosed hereinin a simplified form as a prelude to the more detailed description thatis presented later.

The present example provides footwear systems utilizing silica derivedgel sheets used as a footwear component in upper linings of thefootwear, such as a toe box. The upper linings provide a cushioning andshock absorption system, particularly in inclined high-heel shoes wherethe toes and MTP (metatarsophalangeal) joints typically bear most of theweight in such shoes and come in contact with the footwear linings. Thematerial advantageously not only provides padding, but also absorbsshock to further reduce force placed on the foot by dissipating energyof each footstep. In addition like material may be disposed in the soleof the shoe under the ball of the foot to provide shock absorption andcushioning below as well.

Many of the attendant features will be more readily appreciated as thesame becomes better understood by reference to the following detaileddescription considered in connection with the accompanying drawings.

DESCRIPTION OF THE DRAWINGS

The present description will be better understood from the followingdetailed description read in light of the accompanying drawings,wherein:

FIG. 1 shows typical Women's shoes.

FIG. 2 shows the typical parts of a shoe.

FIG. 3 shows a cushioning and shock absorbing material suitable for usein lining a toe box.

FIG. 4 shows a shoe component that will be formed into an assembled shoetoe box having the cushioning and shock adsorbing material coupled to anouter decorative piece.

FIG. 5 shows a shoe including a toe box with cushioning and shockabsorbing material.

FIG. 6 shows a process for building a gel cushioned shoe. Gel materialis attached to desired shoe components.

Like reference numerals are used to designate like parts in theaccompanying drawings.

DETAILED DESCRIPTION

The detailed description provided below in connection with the appendeddrawings is intended as a description of the present examples and is notintended to represent the only forms in which the present example may beconstructed or utilized. The description sets forth the functions of theexample and the sequence of steps for constructing and operating theexample. However, the same or equivalent functions and sequences may beaccomplished by different examples.

The examples below describe a footwear system and method having footwearupper linings for cushioning and shock absorption. Although the presentexamples are described and illustrated herein as being implemented in ahigh healed women's shoe, the system described is provided as an exampleand not a limitation. As those skilled in the art will appreciate, thepresent examples are suitable for application in a variety of differenttypes of shoes including women's shoes with a variety of heel heights,men's shoes and the like. In addition the linings for cushioning andshock absorption may be provided as an aftermarket accessory, such as aninsert, or the like for existing shoes without such shock absorbing toeboxes.

FIGS. 1-2 show typical women's shoes, and the nomenclature of commonshoe components, or sub assemblies.

FIG. 1 shows typical Women's shoes. High heel shoes typically shiftweigh onto the toes, and ball of the foot. The higher the heel the morepronounced the effect. Unfortunately if the shoe is very comfortable(with a low heel and a wide toe box) it is typically not viewed asstylish. The more stylish the shoe typically has higher levels ofdiscomfort. In short they hurt.

However, this invention may be applied to a variety of foot wear toalleviate foot pain and discomfort, due to the shock of walking onheels. This invention applies to those shoe components that touch (orare in contact through a lining) the skin of a user, including footwearhaving as little contact as that of a sandal, and to as much contact asthat of a tall boot.

FIG. 2 shows the typical internal parts of a shoe. Internal parts of theshoe typically contact the foot of a wearer. They are typically providedto prevent wear to the shoe from a foot rubbing against the shoeinterior. Footwear uppers may include internal components (which contacta user's foot) and pattern pieces (which are the exterior ornamentationand visual parts of an upper). Components (which make up the basicstructure of the shoe) may include the toe box formed from avamp-corresponding to the vamp lining 9 in outline) including toe boxlining 11 (which is typically a flimsy fabric, or a rigid material toprovide an aesthetically pleasing shape), heel counter, counter lining,vamp lining 9, and quarter linings, and while there are several othercomponents, the internal components are particularly applicable to theinvention described below as the invention provides interior shockabsorbing components that provide improved comfort to a wearer notpresent in the typical shoe.

Currently, materials used as linings may be various types of leathers(pigskin, calfskin, kidskins, and the like) and textiles which aretypically thin (so as not to take up available space for the foot) anddurable (which have been thought to require a firm and sturdy materialin current practice) with exposed and protruding stitching, all of whichare not comfortable on a user's feet given the amount of repetitiveblunt force to a foot that is encountered in walking, running andjumping.

The toe box 11 is the portion of a shoe that surrounds the toes, andtypically is positioned under the vamp (which is similar to the vamplining 9 shown, or front toe portion of the shoe. Toe boxes that do notfit can cause injuries and foot deformities. Toe boxes can come in avariety of shapes and styles some of which are a matter of fashion, andsome of which are designed for specialized functions. In the case ofhigh heeled shoes the toes, due to the heel being positioned higher, areoften forced into the toe box compressing the toes together, and causingthe big toe to point towards the other toes, and not in a straight line.Toe boxes also often taper symmetrically; from both sides oftendeforming the toes since toes do not naturally taper. Additionally inhigh heeled shoes, the toe box must typically be made to be somewhattight—otherwise the heel of the shoe will tend to be loose causingdiscomfort and ill fit of the shoe.

FIGS. 3-5 show a footwear system and method having footwear upperlinings for cushioning and shock absorption.

FIG. 3 shows an exemplary shock absorbing material 301 that may be usedto form a toe box. The exemplary material is typically a shock absorbingsilicone gel-such as is used in medical burn treatment, or equivalent,that tends to have, in addition to padding properties the advantageousquality of absorbing and dissipating energy applied to it, which reducesthe impact felt by one's foot, over that of a typical toe box.

Silicone (or equivalent energy absorbing material) gel sheets arecurrently used as a scar treatment. An exemplary material for use asfootwear upper linings for cushioning and shock absorption, is themedical-grade (or non-medical grade equivalent) silicone gel sheets 301that can be customized to various thicknesses. medical-grade silicone iswell known to those skilled in the art and typically made fromcross-linked polydimethylsiloxane polymer that may be reinforced with asilicone membrane backing In alternative examples the silicone gel maybe pre-formed, or molded, if desired.

FIG. 4 shows a shoe component that will be formed into an assembled shoetoe box having the cushioning and shock adsorbing material coupled to anouter decorative piece. Here the outer vamp piece 401 is shown in planview from the top and from the side. A conventional Vamp would be fittedaround a toe box and attached to a sole of the shoe. Here a lining 407is attached directly to the vamp 401 is bonded with bonding material 403to the shock absorbing gel material 301. The gel 301 may include afabric backing or lining on one or both sides. Typically the backingmaterial if present is chosen for comfort and durability. In additionthe backing material 403 disposed between the outer decorative pieces(vamp) 401 may be chosen to be rigid enough to give the shoe shape, withthat on the opposite side (if any) chosen for comfort. Similar bondingprocesses may be used to attach the gel 301 to other components such asthe heel sole or the like.

A ⅛″ thickness of shock absorbing material 301 may be useful for theheel and quarter linings, while the vamp lining and toe box 401 liningsmay be as thick as ¼″ in order to absorb the higher levels of shock fromtoes pushing into the toe box area of the shoe. This sheeting can besupplied by the manufacturer with or without fabric backings 405 oneither or both sides of the shock absorbing material 301 and the idea isthat these sheets (after being cut to the required lining pattern 401)would be attached, bonded or coupled (via glue, fusing, stitching, orthe like) 403 to the external shoe's upper 401, such that the liningpart 301 that touches, or is in close proximity through a lining, thefoot's skin, is very soft, durable, shock absorbing, and eventemperature resistant made from a material designed specifically tomitigate friction points while not breaking down from friction ortemperature. A visit to any shoe store and running your fingers alongthe interior linings will show anybody that this is not a method ofmanufacturing or component currently used in this manner.

FIG. 5 shows a shoe system 500 including a toe box with cushioning andshock absorbing material. The toe box described above may advantageouslybe combined with cushioning and shock absorbing members in the innersole of the shoe, including that as described in U.S. Pat. No. 8,490,297issued Jul. 23, 2013 the contents of which are incorporated byreference. This reference describes a shock absorbing structure for theball of the foot 501 that may be included in the shoe system 500. Theshoe system has a toe box that surrounds the top and sides of the footwith a shock absorbing gel material 301. The system 500 may also includeshock absorbing structure for the ball of the foot 501. And finally theshock absorbing gel material 301 may be included in the heel or otherparts of the shoe as desired. For example gel in a heal strap may bethinner than that of the toe box or other parts of the shoe. Gelmaterial tends to be thicker towards the front of a shoe as in a highheel shoe more force against the foot is present where the foot isforced downward. The attached appendix

FIG. 6 shows a process for building a gel cushioned shoe. Gel materialis attached to desired shoe components 601. Cushioning for the ball ofthe foot is disposed in the sole 605. And finally the various shoe partsincluding cushioning gel materials are assembled into a show 603.

Those skilled in the art will realize that the process sequencesdescribed above may be equivalently performed in any order to achieve adesired result. Also, sub-processes may typically be omitted as desiredwithout taking away from the overall functionality of the processesdescribed above.

1. A pressure-responsive footwear system, comprising: asubstantially-inclined shoe having a posterior portion and an anteriorportion and a middle portion disposed there between, and further havinga foot-supporting portion comprising: a unitary, rigid sole portion thatis generally incompressible in response to a force applied by a user'sfoot during use, wherein: the rigid sole portion is either a midsole, oran outsole, or a unitary combination of a midsole and an outsole; therigid sole portion includes and extends for at least a first thicknessbetween each of an upwardly-orientated foot-engaging surface and adownwardly-orientated ground-engaging surface, the foot-engaging surfaceincludes a first outer boundary, and either or both of a posteriorportion and a middle portion of the foot-engaging surface is inclined atan angle equal to or greater than approximately fifteen degrees along anapproximately anterior-posterior axis, a first recess formed into thefoot-engaging surface of the rigid sole portion and positioned withinthe outer boundary thereof, the recess presenting an opening at thefoot-engaging surface and further extending into but not fully throughthe rigid sole portion, wherein: a cross-sectional depth profile of therecess is asymmetric along an anterior-posterior plane extending throughthe recess, a deeper first portion or the recess is disposed closer tothe anterior end of the shoe than is a second shallower portion of therecess, and inner surfaces of the recess are concavely curved ratherthin angular; a first leak-resistant, flexible bladder disposed mainlywithin and conforming dimensionally relative to an inner configurationof the recess; a volume of relatively viscous filler material disposedwithin and filling the bladder, wherein: the filler material imparts asuitably high tension at a surface of the bladder, a portion of thebladder extends above the foot-engaging surface immediately surroundingthe opening of the recess, and in response to a three applied downwardlyby a portion of a user's foot upon a portion of the bladder during use,the rigid sole portion prevents downward and lateral displacement of thefiller material, and instead redirects displacement of the fillermaterial upwardly toward portions of the user's foot located adjacentlyto the force-applying portion of the user's foot and a shock absorbingtoe box.
 2. A shoe, comprising: a rigid sole portion including aground-engaging surface, an opposing foot-engaging surface, and a rigidfoot-supporting material disposed there between, wherein: the rigid soleportion is either a midsole, or an outsole, or a unitary combination ofa midsole and an outsole; a first thickness of an anterior portion ofthe rigid sole portion is equal to or greater than one quarter inch, andone or both of a posterior portion and a middle portion of thefoot-engaging surface is inclined at an angle equal to or greater thanapproximately fifteen degrees (1
 5. degree.) along an approximatelyanterior-posterior axis of the shoe; a recess formed into the rigid soleportion with an opening thereto presented at the foot-engaging surfaceand having an asymmetrical depth profile, wherein; a first portion ofthe recess is formed to a greater depth into the rigid sole portion ofthe shoe than is at least a second portion of the recess, the firstportion of the recess is disposed more toward the anterior of the shoethan is the second portion of the recess, the recess does not extendfully through the rigid sole portion from the opening at thefoot-engaging surface to the ground-engaging surface, and adjacent innersurfaces of the recess are coupled by a curved junction disposed therebetween; a replaceable, force-deformable bladder disposed mainly withinthe recess, wherein a portion of the bladder extends downwardly into therecess below the foot-engaging surface and another portion thereofprotrudes upwardly through the opening and above the foot-engagingsurface; a volume of relatively viscous filler material disposed withinthe bladder, wherein: the filler material imparts a suitably hightension at a surface of the bladder, a portion of the bladder extendsabove the foot-engaging surface immediately surrounding the opening ofthe recess, and in response to a force applied downwardly by a portionof a user's foot upon a portion of the bladder during use, the rigidsole portion prevents downward and lateral displacement of the fillermaterial, and instead redirects displacement of the filler materialupwardly toward portions of the user's foot located adjacently to theforce-applying portion of the user's foot; and an upper portion coupledwith the rigid sole portion and configured to receive and retain auser's foot in position relative to both the foot-engaging surface andthe cushioning device, wherein the bladder underlies either or both of ametatarsal-phalangeal junction or a posterior portion of the calcaneusbone of the foot and a shock absorbing toe box.
 3. A shoe toe boxcomprising: an outer decorative piece; and an inner shock absorbingsheet, in which the sheet is coupled to the outer decorative piece.
 4. Ashoe comprising a shock absorbing toe box a shock absorbing pad disposedin a shoe sole and positioned under a ball of the foot.